Weighted club heads and methods for forming the same

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application of U.S. patent application Ser. No. 11/070,308, filed Mar. 1, 2005 now abandoned, and a continuation-in-part application of U.S. patent application Ser. No. 11/942,531, filed Nov. 19, 2007 now abandoned. The disclosure of the related applications listed above is incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates generally to sports equipment, and relates more particularly to weighted club heads and methods for forming the same.

BACKGROUND

To increase the moment of inertia of the club, heel and/or toe weights may be incorporated into a club head. This increased moment of inertia may reduce club head twisting if a golf ball impacts the strike face of the club head at an off-center location. To increase the moment of inertia, some club heads utilize a low density material for the club head body in conjunction with a higher density material for the heel and toe weights.

In contrast to existing golf clubs, the methods, apparatus, and articles of manufacture described herein may allow one or more weights to be easily and securely attached to the club head body. Further, the methods, apparatus, and articles of manufacture described herein may allow variable or custom weights to be interchanged after the club head has been manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> illustrates a partially exploded, perspective view of a club head.

<figref idref="DRAWINGS">FIGS. 2-4</figref> illustrate a side view of a portion of the club head of <figref idref="DRAWINGS">FIG. 1</figref> during different stages of assembly.

<figref idref="DRAWINGS">FIG. 5</figref> illustrates the side view of <figref idref="DRAWINGS">FIG. 4</figref> and highlights an oblique distribution of stresses across a fastener of the club head of <figref idref="DRAWINGS">FIG. 1</figref>.

<figref idref="DRAWINGS">FIG. 6</figref> illustrates the side view of <figref idref="DRAWINGS">FIG. 4</figref> and shows the weight of the club head secured to the body of the club bead along three axes.

<figref idref="DRAWINGS">FIG. 7</figref> illustrates a perspective view of a second club head having the weight of <figref idref="DRAWINGS">FIG. 1</figref> and another weight.

<figref idref="DRAWINGS">FIG. 8</figref> illustrates a flowchart for a method of forming a club head.

<figref idref="DRAWINGS">FIG. 9</figref> illustrates the side view of <figref idref="DRAWINGS">FIG. 4</figref> and highlights the interlocking of the weight and body of the club head relative to concentric circles about an axis substantially normal to a front surface of the body.

For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well known features and techniques may be omitted to avoid unnecessarily obscuring of the drawings. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of different embodiments. The same reference numerals in different figures denote the same elements.

The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the present disclosure are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the weighted club heads and methods for forming the same described herein are, for example, capable of operation in orientations other than those illustrated or otherwise described herein.

The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements, mechanically and/or otherwise. Coupling may be for any length of time, e.g., permanent or semi-permanent or only for an instant. The absence of the word “removably,” “removable,” and the like near the word “coupled,” and the like does not mean that the coupling, etc. in question is or is not removable.

DESCRIPTION

The present disclosure relates to a club head having a body fitted with heel and/or toe weights attached in advantageous manners. In accordance with one embodiment, a method of forming a club head includes providing a body having an end portion (e.g., a heel or a toe end of the club head) wherein the body end portion includes a lower surface and a boss extending therefrom. The method also includes providing a weight having a top surface and a cavity configured to receive the boss and inserting the boss into the cavity in the weight. The insertion can include rotating the weight such that the boss interlocks with the cavity and such that at least a portion of the top surface of the weight contacts at least a portion of the lower surface of the end portion of the body. In accordance with the same or different embodiment, the weight further includes a protrusion having a concave surface and the body has a corresponding convex surface. In this embodiment, the insertion of the boss into the cavity can further include rotating the weight about an axis extending through the body such that the concave surface of the weight bears on the convex surface of the body.

In the same or a different embodiment, a method of forming a club head can include providing a body comprising a front surface, a rear surface, an arcuate body surface between the front and rear surfaces, and a first end portion between the front and rear surfaces, where the first end portion comprises a lower surface and a boss extending therefrom. The method can further include providing a weight extending from the front surface of the body to the rear surface of the body, where the weight comprising a top surface, a cavity to receive the boss, and a protrusion comprising an arcuate weight surface. The weight can be interlocked with the first end portion by, for example, rotating the weight about an axis normal to the front surface of the body, interlocking the arcuate weight surface and the arcuate body surface against each other, and interlocking the boss and the cavity against each other.

Proceeding with the figures, <figref idref="DRAWINGS">FIG. 1</figref> illustrates a partially exploded, perspective view of club head <b>100</b> comprising body <b>102</b> and weight <b>104</b> in accordance with one embodiment. Body <b>102</b> comprises body end portion <b>144</b> at a heel end of club head <b>100</b>. In a different embodiment, body end portion <b>144</b> could be located at a toe end of club head <b>100</b> instead. <figref idref="DRAWINGS">FIG. 1</figref> also shows club head <b>100</b> coupled to shaft <b>171</b> at hosel <b>172</b>. Although shown as a cavity into top side <b>161</b> of club head <b>100</b>, hosel <b>172</b> also can protrude from body <b>102</b> in other embodiments. Club head <b>100</b> is shown as a putter in the present embodiment, but in other embodiments could comprise other types of heads such as a driver head, a hybrid head, and a fairway wood head, among others. The teachings in this disclosure are not limited to any specific type of club or club head.

<figref idref="DRAWINGS">FIGS. 2-4</figref> show the insertion of boss <b>106</b> within cavity <b>108</b> during assembly or formation of an exemplary putter head. For example, <figref idref="DRAWINGS">FIG. 2</figref> illustrates a side view of weight <b>104</b> and part of body <b>102</b> at an initial stage of interlocking. <figref idref="DRAWINGS">FIG. 3</figref> illustrates a side view of weight <b>104</b> and part of body <b>102</b>, where body <b>102</b> is being rotated in the direction of arrow <b>350</b> to be interlocked, and <figref idref="DRAWINGS">FIG. 4</figref> illustrates a side view of weight <b>104</b> and part of body <b>102</b> fully interlocked.

As shown in <figref idref="DRAWINGS">FIG. 3</figref>, weight <b>104</b> can be positioned such that boss <b>106</b> is aligned to enter cavity <b>108</b>, while concave weight surface <b>204</b> is placed in contact with convex body surface <b>202</b> of body <b>102</b>. As shown in <figref idref="DRAWINGS">FIG. 1</figref>, convex body surface <b>202</b> is located at the rear of body <b>102</b> and is not located in the middle or the front of body <b>102</b>. Similarly, concave weight surface <b>204</b> is located at the rear of club head <b>100</b> when weight <b>104</b> is interlocked with body <b>102</b>. In other embodiments, convex body surface <b>202</b> and concave weight surface <b>204</b> can be located at other portions of club head <b>100</b>.

Convex body surface <b>202</b> can provide a point of leverage to assist rotating weight <b>104</b> into engagement with boss <b>106</b>. Weight <b>104</b> is then further rotated about axis <b>205</b>, which also generally corresponds to the center of curvature of arcuate surfaces of weight <b>104</b> and body <b>102</b> (e.g., surfaces <b>110</b>, <b>112</b>, <b>120</b>, and <b>122</b> shown in <figref idref="DRAWINGS">FIGS. 1 and 2</figref>). Weight <b>104</b> is rotated until interlocked with body <b>102</b>, e.g., until juncture area <b>210</b> of weight <b>104</b> at least partially contacts juncture area <b>212</b> of body <b>102</b>, as shown in <figref idref="DRAWINGS">FIG. 4</figref>.

More specific details on the interlocking between different elements of weight <b>104</b> and body <b>102</b> are described in more detail below. In the present example, club head <b>100</b> comprises strike face <b>152</b>, and strike face <b>152</b> comprises front surface <b>142</b> of body <b>102</b> and front surface <b>140</b> of weight <b>104</b>. Surfaces <b>142</b> and <b>140</b> are substantially planar with each other when boss <b>106</b> and cavity <b>108</b> are wedged together, as shown in <figref idref="DRAWINGS">FIG. 4</figref>. Also in the present example, club head <b>100</b> comprises sole <b>162</b>, and sole <b>162</b> comprises bottom surface <b>260</b> of weight <b>104</b> and bottom surface <b>262</b> of body <b>102</b>. In the present embodiment, surfaces <b>260</b> and <b>262</b> are substantially planar with each other when boss <b>106</b> and cavity <b>108</b> are wedged together, as shown in <figref idref="DRAWINGS">FIG. 4</figref>. In a different embodiment, sole <b>162</b> could comprise a curvature, such as a convex curvature along a length of sole <b>162</b>. In the same embodiment, surfaces <b>260</b> and <b>262</b> could be correspondingly curved to the curvature of sole <b>162</b>.

Starting with body <b>102</b> of club head <b>100</b>, front surface <b>142</b> and rear surface <b>143</b> can be located at opposite sides of body <b>102</b>, as shown in <figref idref="DRAWINGS">FIG. 1</figref>. In some examples, front surface <b>142</b> could be part of the strike face of the club head <b>100</b>, while tear surface <b>143</b> could be part of the backside of club head <b>100</b>. Body <b>102</b> also comprises body end portion <b>144</b> located between front and rear surfaces <b>142</b>-<b>143</b>, and located towards a heel portion of body <b>102</b>. In a different embodiment, body end portion <b>144</b> could be located elsewhere with respect to body <b>102</b>, such as proximate to a toe portion of body <b>102</b>. Convex body surface <b>202</b> of body <b>102</b> is also located between front and rear surfaces <b>142</b>-<b>143</b>, proximate to body end portion <b>144</b>. Body end portion <b>144</b> comprises juncture area <b>212</b> facing substantially opposite to top side <b>161</b> of body <b>102</b> in the present example. In addition, boss <b>106</b> extends from juncture area <b>212</b>, and comprises two generally arcuate surfaces <b>110</b> and <b>112</b> at opposite sides of boss <b>106</b>, and two generally planar surfaces <b>116</b> and <b>114</b> at opposite sides of boss <b>106</b>. Arcuate surfaces <b>110</b> and <b>112</b> configure boss <b>106</b> as an arc that extends from juncture area <b>212</b> and away from body <b>102</b> in a concave arc with respect to sole <b>162</b> of body <b>102</b>.

Club head <b>100</b> also comprises weight <b>104</b> configured to interlock with body end portion <b>144</b>, where weight <b>104</b> comprises a density greater than a density of body <b>102</b>. In some examples, weight <b>104</b> could be referred to as a ballast. In one embodiment, weight <b>104</b> can be heavier than body <b>102</b>. In another embodiment, weight <b>104</b> can be approximately 5 to 50 percent of the total mass of club head <b>100</b>, which does not include shaft <b>171</b>.

As illustrated in the sequence of <figref idref="DRAWINGS">FIGS. 2-4</figref>, weight <b>104</b> and body end portion <b>144</b> are configured to interlock with each other upon a rotation of weight <b>104</b> about axis <b>205</b>, where axis <b>205</b> is substantially normal to front surface <b>142</b> of body <b>102</b>. Axis <b>205</b> is also located at sole <b>162</b> of club head <b>100</b> in the present example. In other examples, where curve <b>162</b> comprises a curvature, axis <b>205</b> could also be located at sole <b>162</b>. Such location of axis <b>205</b> can permit extremity <b>292</b> of convex body surface <b>202</b> (<figref idref="DRAWINGS">FIG. 4</figref>) to be less acute and/or substantially perpendicular relative to sole <b>162</b>. This can be beneficial, for example, to restrict extremity <b>292</b> from cutting into turf during a putting stroke, and/or to prevent extremity <b>292</b> from picking up dirt.

Weight <b>104</b> can extend from front surface <b>142</b> to rear surface <b>143</b> when interlocked with body end portion <b>144</b>, and comprises juncture area <b>210</b>, cavity <b>108</b>, and protrusion <b>130</b>. In the present example, juncture area <b>210</b> comprises a top surface of weight <b>104</b>, and protrusion <b>130</b> comprises concave weight surface <b>204</b> complementary to convex body surface <b>202</b> of body <b>102</b>. Both concave weight surface <b>204</b> and convex body surface <b>202</b> are configured to slide across each other upon the rotation of weight <b>104</b> about axis <b>205</b>. When weight <b>104</b> is interlocked with body end portion <b>144</b> after the rotation of weight <b>104</b> about axis <b>205</b> as shown in <figref idref="DRAWINGS">FIG. 4</figref>, juncture area <b>212</b> of body end portion <b>144</b> lies adjacent to and on top of juncture area <b>210</b> of weight <b>104</b> such that convex body surface <b>202</b> is located below and wedged against concave weight surface <b>204</b>. In some examples, press-fit <b>410</b> (<figref idref="DRAWINGS">FIG. 4</figref>) may be formed between concave weight surface <b>204</b> and convex body surface <b>202</b> when concave weight surface <b>204</b> and convex body surface <b>202</b> wedge together. As a result, concave weight surface <b>204</b> and convex body surface <b>202</b> can press against each other when weight <b>104</b> is interlocked with body end portion <b>144</b>, thereby restricting potential vibrations of weight <b>104</b> relative to body <b>102</b>.

Cavity <b>108</b> of weight <b>104</b> is configured to receive boss <b>106</b> of body <b>102</b> when weight <b>104</b> and body end portion <b>144</b> are interlocked with each other. In the present example, cavity <b>108</b> comprises arcuate surface <b>122</b> complimentary to arcuate surface <b>112</b> of boss <b>106</b>, and two generally planar surfaces <b>126</b> and <b>124</b> complimentary to planar surfaces <b>116</b> and <b>114</b>, respectively, of boss <b>106</b>. Arcuate surfaces <b>112</b> and <b>122</b> are configured to slide across each other upon the rotation of weight <b>104</b> about axis <b>205</b>. Cavity <b>108</b> also comprises arcuate surface <b>120</b> complimentary to arcuate surface <b>110</b> of boss <b>106</b>, but in a different example, surfaces <b>120</b> and <b>110</b> need not be arcuate and/or complementary to each other. Nevertheless, in the present example, arcuate surfaces <b>120</b> and <b>110</b> are configured to slide across each other upon the rotation of weight <b>104</b> about axis <b>205</b>.

Club head <b>100</b> can be configured such that, when weight <b>104</b> is interlocked with body end portion <b>144</b>, juncture area <b>212</b> of body end portion <b>144</b> lies adjacent to juncture area <b>210</b> of weight <b>104</b> such that arcuate surface <b>122</b> of cavity <b>108</b> is wedged against arcuate surface <b>112</b> of boss <b>106</b>, thereby wedging boss <b>106</b> against cavity <b>108</b>. In the present example, arcuate surface <b>120</b> of weight <b>104</b> is similarly wedged against arcuate surface <b>110</b> of boss <b>106</b>. In some examples, press-fit <b>420</b> (<figref idref="DRAWINGS">FIG. 4</figref>) may be formed between surfaces <b>112</b> and <b>122</b>, and/or between surfaces <b>110</b> and <b>120</b>, when boss <b>106</b> and cavity <b>108</b> wedge together. Boss <b>106</b> and cavity <b>108</b> may thus press against each other when weight <b>104</b> is interlocked with body end portion <b>144</b>, thereby further restricting potential vibrations of weight <b>104</b> relative to body <b>102</b>.

Club head <b>100</b> can also comprise, as in the present example, fastener <b>250</b> configured to be inserted through weight <b>104</b> and into boss <b>106</b> to secure weight <b>104</b> to body end portion <b>144</b> of body <b>102</b>. In examples comprising press-fits <b>410</b> and/or <b>420</b>, fastener <b>250</b> can place club head <b>100</b> in a stressed condition when securing weight <b>104</b> to body <b>102</b>. The stressed condition can be beneficial in some embodiments for reducing or restricting vibrations between weight <b>104</b> and body <b>102</b>. In the present example, fastener <b>250</b> comprises a machine screw, but fastener <b>250</b> may comprise different types of screws or other elements for fastener <b>250</b>, such as nails, rivets, pins, soldering material, brazing material, magnets, and/or adhesives like glue or epoxy. Alternatively, fastener <b>250</b> can be eliminated when, for example, at least one of boss <b>106</b> or weight <b>104</b> comprises a magnet and the other one of boss <b>105</b> and weight <b>104</b> comprises a magnet (of opposite polarity) or a metal.

As disclosed herein, body <b>102</b> and/or weight <b>104</b> can comprise any suitable metal, plastic, composite material, or combination thereof. In accordance with one embodiment, body <b>102</b> comprises a material such as titanium or a high-purity titanium alloy, e.g., commercial pure grade 2 titanium, and weight <b>104</b> comprises a material whose density is greater than that of body <b>102</b>, e.g., tungsten. While body <b>102</b> and weight <b>104</b> may be fabricated from a metallic material, the present disclosure is not so limited. For example, the primary constituent of body <b>102</b> can include a composite or plastic material having the desired characteristics.

Depending upon the selected material or materials, body <b>102</b> may be fabricated using any suitable process now known or later developed, including a variety of conventional casting methods such as investment-casting, forging, powdered-metal processing, and/or metal machining. In one embodiment, body <b>102</b> can be formed via a suitable casting process, and afterwards, the assembled unit (with heel and/or toe weights) can be milled to finish the various exposed surfaces.

The shape and materials used for body <b>102</b> and weight <b>104</b> can be defined by any suitable factors, including, for example, club head type, desired moment of inertia (e.g., the polar moment of inertia around an axis normal to the club head sole), desired center of gravity, desired aesthetic properties (e.g., visual cues provided by the club head's contours as viewed from above during play), and/or the desired weight, mass, and density. In this regard, the exemplary club head shapes depicted in herein are for illustrative purposes only and are not limitations of the club head.

Continuing with the figures, <figref idref="DRAWINGS">FIG. 5</figref> illustrates the side view of <figref idref="DRAWINGS">FIG. 4</figref> and highlights an oblique distribution of stresses across a fastener. Fastener <b>250</b> is configured in the present embodiment to distribute shear and tensile stresses across an oblique cross-section <b>251</b> of fastener <b>250</b>. The shear and tensile stresses are generated as a result of interactions between convex body surface <b>202</b> and concave weight surface <b>204</b>, and/or between boss <b>106</b> and cavity <b>108</b>, when weight <b>104</b> and body end portion <b>144</b> of body <b>102</b> are interlocked. For example, because of the arcuate shape of arcuate elements (such as boss <b>106</b>, cavity <b>108</b>, convex body surface <b>202</b>, and concave weight surface <b>204</b>), weight <b>104</b> can normally only dislodge from body end portion <b>144</b> in an arcuate path opposite to path <b>550</b> initially followed to interlock weight <b>104</b> and body end portion <b>144</b> together. In some cases, interactions between the arcuate elements could act upon fastener <b>250</b> as resultant stresses <b>590</b>, which are angled obliquely with respect to a length of fastener <b>250</b> and which are spread across oblique cross-section <b>251</b> of fastener <b>250</b>. Resultant stresses <b>590</b> could be a composite of shear stresses <b>591</b> and tensile stresses <b>592</b> acting upon fastener <b>250</b>. In some examples, resultant stresses <b>590</b> could be a product of press-fits <b>410</b> and/or <b>420</b> (<figref idref="DRAWINGS">FIG. 4</figref>) between the arcuate elements of club head <b>100</b>.

<figref idref="DRAWINGS">FIG. 6</figref> illustrates the side view of <figref idref="DRAWINGS">FIG. 4</figref> and shows weight <b>104</b> secured to body <b>102</b> along three axes. In the present embodiment, boss <b>106</b> and cavity <b>108</b> are configured to restrict a displacement of weight <b>104</b> along three axes, such as axes <b>601</b>-<b>603</b> in <figref idref="DRAWINGS">FIG. 6</figref>. The three axes are substantially perpendicular to each other relative to body <b>102</b>. In some examples, the restriction of the displacement of weight <b>104</b> may be further enhanced by the interacting forces from press-fit <b>420</b>.

For example, in the present embodiment, surface <b>110</b> of boss <b>106</b> and surface <b>120</b> of weight <b>104</b> are wedged together to restrict a displacement of weight <b>104</b> along axis <b>602</b> towards body <b>102</b>, and along axis <b>601</b> towards sole <b>162</b> of club head <b>100</b>. Convex body surface <b>202</b> and concave weight surface <b>204</b> serve a similar function as surfaces <b>110</b> and <b>120</b>. Also, surface <b>112</b> of boss <b>106</b> and surface <b>122</b> of weight <b>104</b> are wedged together to restrict a displacement of weight <b>104</b> along axis <b>602</b> away from body <b>102</b>, and along axis <b>601</b> towards top side <b>161</b> of club head <b>100</b>. In addition, surfaces <b>114</b> and <b>116</b> of boss <b>106</b> (<figref idref="DRAWINGS">FIG. 1</figref>) are wedged against surfaces <b>124</b> and <b>126</b>, respectively, of weight <b>104</b> (<figref idref="DRAWINGS">FIG. 1</figref>) to restrict displacement of weight <b>104</b> along axis <b>603</b>.

In some embodiments, club head <b>100</b> can also comprise an alternate weight (not shown) similar to weight <b>104</b>, but having a different mass than that of weight <b>104</b>. The alternate weight can be configured to interlock with body end portion <b>144</b> upon a rotation of the alternate weight about axis <b>205</b>, similar to the way weight <b>104</b> interlocks with body end portion <b>144</b>. The provision of the alternate weight can permit the custom weighting of club head <b>100</b> for different situations and/or preferences.

<figref idref="DRAWINGS">FIG. 7</figref> illustrates a perspective view of a club head <b>700</b> having two weights. Club head <b>700</b> is similar to club head <b>100</b> (<figref idref="DRAWINGS">FIGS. 1-6</figref>), but comprises body <b>702</b> instead of body <b>102</b>, and includes body end portion <b>744</b> substantially opposite body end portion <b>144</b>. Club head <b>700</b> further comprises weight <b>704</b>, similar to weight <b>104</b>, but configured to interlock instead with body end portion <b>744</b>. Weight <b>704</b> can interlock with body end portion <b>744</b> similar to the way that weight <b>104</b> interlocks with body end portion <b>144</b>, as described above. In the present example, weights <b>104</b> and <b>704</b> are absent from a portion of body <b>702</b> between body end portions <b>144</b> and <b>744</b>, such that weights <b>104</b> and <b>704</b> are not contiguous with each other and are also not adjacent to each other. The placement of weights <b>104</b> and <b>704</b> toward the antipodal extremes of the toe and heel ends of club head <b>700</b> can increase the moment of inertia of club head <b>700</b>. Weights <b>104</b> and <b>704</b> are also kept low and close to sole <b>162</b>, which can lower the center of mass of club head <b>700</b> and provide other benefits.

Skipping ahead in the figures, <figref idref="DRAWINGS">FIG. 9</figref> illustrates the side view of <figref idref="DRAWINGS">FIG. 4</figref> and highlights the interlocking of weight <b>104</b> and body <b>102</b> relative to concentric circles about axis <b>205</b>. In some examples, each of arcuate surfaces <b>110</b> and <b>112</b> of boss <b>106</b>, arcuate surfaces <b>120</b> and <b>122</b> of cavity <b>108</b>, concave weight surface <b>204</b>, and convex body surface <b>202</b> can be configured to form portions of concentric circles relative to axis <b>205</b>. For example, as shown in <figref idref="DRAWINGS">FIG. 9</figref>, concave weight surface <b>204</b> and convex body surface <b>202</b> can form a portion of circle <b>910</b>; arcuate surfaces <b>112</b> and <b>122</b> can form a portion of circle <b>920</b>; and arcuate surfaces <b>110</b> and <b>120</b> can form a portion of circle <b>930</b>. Each of circles <b>910</b>, <b>920</b>, and <b>930</b> are concentric about axis <b>205</b>. Such an arrangement can facilitate and/or guide the rotation of weight <b>104</b> towards body end portion <b>144</b> as boss <b>106</b> is wedged against cavity <b>108</b>.

Turning to the remaining figure, <figref idref="DRAWINGS">FIG. 8</figref> illustrates a flowchart for method <b>800</b> of assembling or forming a club head. In some examples method <b>800</b> can comprise a portion of a manufacturing process. In the same or different examples, the club head of method <b>800</b> can be similar to club head <b>100</b> (<figref idref="DRAWINGS">FIGS. 1-6</figref> and <b>9</b>), or club head <b>700</b> (<figref idref="DRAWINGS">FIG. 7</figref>).

Block <b>810</b> of method <b>800</b> involves providing a body comprising an arcuate body surface and a first end portion, wherein the first end portion comprises a boss extending therefrom. In the present example, the boss of method <b>800</b> extends from a lower surface of the first end portion, similar to juncture area <b>212</b> of body end portion <b>144</b> (<figref idref="DRAWINGS">FIGS. 1-4</figref>). In some examples, the body of block <b>810</b> can be similar to body <b>102</b> (<figref idref="DRAWINGS">FIGS. 1-6</figref>) and/or to body <b>702</b> (<figref idref="DRAWINGS">FIG. 7</figref>). The first end portion of the body can be similar to one of body end portions <b>144</b> (<figref idref="DRAWINGS">FIGS. 1-6</figref> and <b>9</b>) or <b>744</b> (<figref idref="DRAWINGS">FIG. 7</figref>), and the boss can be similar to boss <b>106</b> (<figref idref="DRAWINGS">FIGS. 1-7</figref> and <b>9</b>). In some examples, the arcuate body surface of the body of block <b>810</b> can be located between front and rear surfaces of the body, where the arcuate body surface can be similar to convex body surface <b>202</b> of body <b>102</b> (<figref idref="DRAWINGS">FIGS. 1-3</figref>).

Block <b>820</b> of method <b>800</b> involves providing a weight comprising an arcuate weight surface and a cavity to receive the boss. The weight can be similar to weight <b>104</b> (<figref idref="DRAWINGS">FIGS. 1-7</figref>), and can extend from the front surface to the rear surface of the body of block <b>810</b>. In some examples, the cavity can be similar to cavity <b>108</b> (<figref idref="DRAWINGS">FIGS. 1-3</figref>), and can be configured to interlock with the boss of block <b>810</b>. The weight can also comprise a protrusion having the arcuate weight surface, which can be similar to weight concave surface <b>204</b> of protrusion <b>130</b> (<figref idref="DRAWINGS">FIGS. 1-7</figref> and <b>9</b>), and can be configured to interlock with the arcuate body surface of block <b>810</b>.

Block <b>830</b> of method <b>800</b> involves interlocking the weight of block <b>820</b> with the first end portion of the body of block <b>810</b>. In some examples, the weight can be interlocked with the first end portion of the body as described above for interlocking weight <b>104</b> to body end portion <b>102</b> through the sequence of <figref idref="DRAWINGS">FIGS. 2-4</figref>. In the same or a different example, block <b>830</b> can comprise aligning a front surface of the weight to be substantially planar with a front surface of the body, and/or rotating the weight into the first end portion of the body to form a portion of a strike face of the club head of method <b>800</b>. The strike face can thus comprise the front surfaces of the weight and the body substantially planar with each other, as described above for strike face <b>152</b> and front surfaces <b>140</b> and <b>142</b> in <figref idref="DRAWINGS">FIG. 1</figref>. The insert of the boss into the cavity can automatically align the front surfaces of the weight and the body to be substantially planar with each other.

In some embodiments, block <b>830</b> comprises sub-block <b>831</b>, comprising rotating the weight about an axis normal to the front surface of the body of block <b>810</b>, where the axis can be similar to axis <b>205</b> in <figref idref="DRAWINGS">FIGS. 1-4</figref>. In the same or different examples, the weight can be rotated about the axis until the bottom surface of the weight is substantially planar with the bottom surface of the body, as described above for bottom surfaces <b>260</b> and <b>262</b> of weight <b>204</b> and body <b>102</b>, respectively, in <figref idref="DRAWINGS">FIG. 1</figref>. In examples where the axis is located adjacent to the sole of the club head, the junction between the weight and the body near the sole, proximate to extremity <b>292</b> of convex body surface <b>202</b> in the example of <figref idref="DRAWINGS">FIG. 4</figref>, can be less acute and/or substantially perpendicular relative to the sole. Being less acute, the junction will be less likely to cut into turf and/or to pick up dirt during a stroke of the club head of method <b>800</b>.

Sub-block <b>831</b> can also comprise positioning an extremity of the arcuate weight surface against an extremity of the arcuate body surface, and then moving the weight against the first end portion of the body in an arcuate path. In the present example, the arcuate path can be as indicated by directional arrow <b>350</b> in <figref idref="DRAWINGS">FIG. 3</figref>. The arcuate path can be traversed as the arcuate weight and body surfaces slide past each other, e.g., when the extremity of the arcuate weight surface moves from a first extremity of the arcuate body surface towards a second extremity of the arcuate body surface. In the present example, the first and second extremities of the arcuate body surfaces can be extremities <b>292</b> and <b>296</b>, respectively, and the extremity of the arcuate weight surface can be extremity <b>294</b>, as illustrated in <figref idref="DRAWINGS">FIGS. 2-4</figref>. In some examples, a press-fit may be formed between concave weight surface <b>204</b> and convex body surface <b>202</b> as extremity <b>294</b> of weight <b>104</b> approaches extremity <b>296</b> of body <b>102</b>.

In the same or a different embodiment, block <b>830</b> can also comprise sub-block <b>832</b>, which comprises interlocking the arcuate body and weight surfaces against each other. Sub-block <b>832</b> can involve pressing the arcuate weight and body surfaces against each other as the weight of block <b>820</b> is pressed against the first end portion of the body of block <b>810</b>. The weight can be pressed against the first end portion along the arcuate path described for sub block <b>831</b> until the top surface of the weight and the lower surface of the first end portion of the body couple together. In some embodiments, sub-block <b>832</b> will create a press-fit between the arcuate weight and body surfaces, similar to press-fit <b>410</b> shown in <figref idref="DRAWINGS">FIG. 4</figref>. In such cases, the arcuate weight and body surfaces could exert forces against each other to secure the weight in place and/or to prevent or restrict vibrations of the weight relative to the body.

Block <b>830</b> can also comprise sub-block <b>833</b> in some embodiments, involving interlocking the boss of the body of block <b>810</b> and the cavity of the weight of block <b>820</b> against each other. In some examples sub-block <b>833</b> can comprise pressing the boss against the cavity as the weight is pressed against the first portion of the body. The box can be pressed against the cavity along the arcuate path described for sub block <b>831</b>, until the top surface of the weight and the lower surface of the first end portion of the body couple together. In some embodiments, sub-block <b>833</b> will also result in the formation of a press-fit, this time between the boss of the body and the cavity of the weight, similar to press-fit <b>420</b> shown in <figref idref="DRAWINGS">FIG. 4</figref>. In such cases, surfaces of the boss and the cavity could exert forces against each other to secure the weight in place and/or to prevent or restrict vibrations of the weight relative to the body.

In the same or a different embodiment, the interlocking of the boss and the cavity in sub-block <b>833</b> can comprise the interlocking of a first surface of the boss against a first surface of the cavity, the interlocking of a second surface of the boss against a second surface of the cavity, and the coupling of a third surface of the boss adjacent to a third surface of the cavity. Such an arrangement can be implemented to restrict a displacement of the weight along three axes substantially perpendicular to each other, such as described in <figref idref="DRAWINGS">FIG. 6</figref> with respect to axes <b>601</b>-<b>603</b> and to surfaces <b>110</b>, <b>120</b>, <b>112</b>, <b>122</b>, <b>114</b>, <b>116</b>, <b>124</b>, and/or <b>126</b>.

For block <b>830</b>, some examples may comprise interlocking an arcuate boss surface of the boss (block <b>810</b>) with an arcuate cavity surface of the cavity (block <b>820</b>) to form a portion of a first circle, while the arcuate weight surface (block <b>820</b>) and the arcuate body surface (block <b>810</b>) form a portion of a second circle. In these examples, the first and second circles are concentric relative to the axis (sub-block <b>831</b>) when the weight and the first end portion of the body are interlocked. As an example, the first and second circles can be similar to circles <b>910</b> and <b>920</b>, and the arcuate boss, cavity, weight, and body surfaces can be similar to surfaces <b>112</b>, <b>122</b>, <b>204</b>, and <b>202</b>, respectively, as shown in <figref idref="DRAWINGS">FIG. 9</figref>. In the same or a different example, the arcuate boss and weight surfaces can be concave, while the arcuate cavity and body surfaces can be convex.

Still in block <b>830</b>, in the same or a different embodiment, a second arcuate boss surface of the boss (block <b>810</b>) can be interlocked with a second arcuate cavity surface of the cavity (block <b>820</b>) to form a portion of a third circle. The third circle can be concentric with the first and second circles about the axis (sub-block <b>831</b>). As an example, the third circle can be similar to circle <b>930</b>, and the second arcuate boss and cavity surfaces can be similar to surfaces <b>110</b> and <b>120</b>, respectively, as shown in <figref idref="DRAWINGS">FIG. 9</figref>. In the same or a different example, the second arcuate boss surface can be convex, while the second arcuate cavity surface can be concave.

In some embodiments, the subparts of block <b>830</b> can be carried out simultaneously, such that the arcuate weight and body surfaces, and the boss and the cavity, could interlock as the weight is rotated about the axis to interlock with the body. In other embodiments, the sequence of sub-blocks <b>832</b> and <b>833</b> can be reversed.

Method <b>800</b> can also comprise block <b>840</b>, which includes coupling a fastener through the weight and into the boss. In some examples, the fastener can be as described above for fastener <b>250</b> securing weight <b>104</b> to body end portion <b>144</b>. The fastener could comprise a screw, as illustrated in <figref idref="DRAWINGS">FIGS. 1-4</figref>, and/or at least one of a nail, a rivet, a pin, a soldering material, a brazing material, a magnet, and/or an adhesive like glue or epoxy. In the same or a different example, the fastener could be inserted along an insertion axis, such as axis <b>601</b> (<figref idref="DRAWINGS">FIG. 6</figref>), through the weight and into the boss, where the insertion axis is different from the axis normal to the front surface of the body.

In some examples, when interlocked, one or more of the arcuate body surface (block <b>810</b>), the arcuate weight surface (block <b>820</b>), the boss (block <b>810</b>), and/or a surface of the cavity (block <b>820</b>) can exert shear and tensile stresses against the fastener along at least two substantially perpendicular axes, such that at least a portion of the shear and tensile stresses are distributed across an oblique cross-section of the fastener. Such a situation can be similar to the one illustrated in <figref idref="DRAWINGS">FIG. 5</figref>, where resultant stresses <b>590</b>, as composites of shear and tensile stresses <b>591</b>-<b>592</b>, are exerted and distributed obliquely across cross-section <b>251</b> of fastener <b>250</b>.

In some embodiments, the interlocking between the weight and the first end portion, and/or the oblique distribution of stresses upon the fastener, can provide greater strength for the club head of method <b>800</b>. For example, in the embodiment of <figref idref="DRAWINGS">FIG. 5</figref>, weight <b>104</b> is restricted to circular path <b>550</b> about axis <b>205</b> as a result of the interlocking of boss <b>106</b> with cavity <b>108</b>, and of body convex surface <b>202</b> with weight concave surface <b>204</b>. Therefore, resultant stresses <b>590</b> upon fastener <b>250</b> can tend to be limited to a direction substantially tangential to circular path <b>550</b>, and therefore obliquely across fastener <b>250</b>. Stresses exerted in other directions upon club head <b>100</b>, including impact forces, can be absorbed directly by interface elements such as boss <b>106</b>, cavity <b>108</b>, body convex surface <b>202</b>, weight concave surface <b>204</b>, juncture area <b>212</b>, and/or juncture area <b>210</b>. This distribution of the impact forces across the interface elements limits the involvement of fastener <b>250</b> in absorbing and/or dissipating such stresses, which can be beneficial in situations where fastener <b>250</b> is comparatively weaker than the interface elements. In addition, the oblique distribution of resultant stresses <b>590</b> across fastener <b>250</b> provides a larger area (e.g., oblique cross-section <b>251</b>) for stress absorption or dissipation across fastener <b>250</b>.

Continuing with method <b>800</b>, a block <b>850</b> can comprise providing an alternate weight configured to interlock with the first end portion when the weight is removed from the body. Block <b>850</b> can be optional, and in some embodiments the alternate weight of block <b>850</b> can be similar to the alternate weight previously described for club head <b>100</b>. When used, the alternate weight can be configured to interlock with the first end portion of the body of block <b>801</b> after the weight of block <b>802</b> is removed.

Method <b>800</b> can also comprise optional block <b>860</b> for providing a second weight and interlocking the second weight with a second end portion of the body. In some examples, the second end portion of the body can be located substantially opposite to the first end portion described in block <b>810</b>. The second weight and the second end portion can be similar in some embodiments to weight <b>704</b> and body end portion <b>744</b>, respectively, as previously described for <figref idref="DRAWINGS">FIG. 7</figref>.

In some examples, one or more of the different parts of method <b>800</b> can be combined into a single block. For example, blocks <b>830</b> and <b>840</b> could be combined in situations where the fastener of block <b>840</b> was integrated with the weight of block <b>830</b>. In the same or a different example, the sequence of one or more of the different steps of method <b>800</b> can be changed. As an example, the sequence of steps blocks <b>810</b> and <b>820</b> could be reversed without affecting the execution of method <b>800</b>, and similarly, the sequence of blocks <b>850</b> and <b>860</b> can be reversed. In the same or a different example, method <b>800</b> can comprise further or different steps consistent with forming and/or manufacturing a club head.

Although the weighted club heads and methods for forming the same have been described with reference to specific embodiments, various changes may be made without departing from the spirit or scope of the present disclosure. Various examples of such changes have been given in the foregoing description. As another example, the particular shape of boss <b>106</b> and cavity <b>108</b> as illustrated are not meant to limit the scope of the present disclosure. For example, while boss <b>106</b> is shown in the figures as a type of solid-of-revolution based on a square or rectangular cross-section, boss <b>106</b> may have any suitable shape and cross-section (e.g., circular, oval, curvilinear, rectilinear, or a combination thereof). Boss <b>106</b> may also be tapered or have another suitably varying cross-section. Considering the different examples and embodiments described above, the weighted club heads and methods for forming the same disclosed herein can permit greater adjustment and customization of different design variables used to craft club heads without unduly compromising the manufacturability and the gaming characteristics of the clubs.

Accordingly, the disclosure of embodiments of the weighted club heads and methods for forming the same is intended to be illustrative of the scope of the application and is not intended to be limiting. It is intended that the scope of this application shall be limited only to the extent required by the appended claims. For example, it will be readily apparent that, in some embodiments, boss <b>106</b> may terminate within weight <b>104</b> (e.g., at approximately half of the thickness of weight <b>104</b>, as shown in <figref idref="DRAWINGS">FIG. 4</figref>), or may instead extend entirely through weight <b>104</b> to form part of sole <b>162</b> of club head <b>100</b>. Additionally, although axis <b>205</b> (<figref idref="DRAWINGS">FIGS. 2-6</figref> and <b>9</b>) is illustrated to be located at sole <b>162</b> of the club head, it can also be located at other portions of the club head. As a further example, in FIG. <b>4</b>., club head <b>100</b> can include convex body surface <b>202</b> and concave weight surface <b>204</b> without the arcuate surfaces of boss <b>106</b> and cavity <b>108</b>, or vice versa. Therefore, the detailed description of the drawings, and the drawings themselves, disclose at least one preferred embodiment of the weighted club heads and methods for forming the same, and may disclose alternative embodiments thereof.

All elements claimed in any particular claim are essential to the weighted club head and/or method for forming the same claimed in that particular claim. Consequently, replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims.

Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.